JWILL wrote:The hard work is always worth it in the long run. Enjoy the updates - keep 'em coming.😃

Thanks! I am having fun and learning all at the same time. I just wish that I had more time and then when I did have the time, the weather would cooperate. Don't have to luxery of having a fancy garage so I just make do when I can. Really hoping to get most of this floor out in the next couple of weeks.

SHIT JUST GOT REAL!!!!While I was on a work trip this week in Charlotte, I went ahead and ordered the replacement front floor from Monkeynut! Its the funky green floor from Gerson and should be here in a few weeks. I have been on a pretty crazy travel schedule for work the last month, so bus work has been limited as usual. I have to go to Houston next week, but after that I am on vacation for three weeks around Christmas and plan on doing a bunch.

Today I was about to get a lot more done on tearing out all the rusty metal up front. Got everything removed except around the steering column (which I am holding off on disconnecting until the last minute in case I have to move the bus, including the pesky spot welds at the front apron! Those were actually pretty easy. I just cut it as close as I could and used a pair of vise grips to work the metal back and forth until it broke free. Still have to grind everything clean and do some Por15 or MasterSeries treatment. All that's left is around the seat pedestals and walk through. Any suggestions on the best way to get that separated cleanly would be appreciated.

The bad news is that my doglegs are a little worse off that I though and will have to do something about them before I weld in the new floor. Only dilemma is that from what I have hear, Gerson is not making the early doglegs anymore! I really don't have the fab skills to screw with all the terrible replacement panels being made right now, so as I see it right now, my only option is finding some donor doglegs for now. If any of you out there reading this have a line on some, please let me know! Or if any one has any suggestions on places to look.

And of course no update would not be complete without my helper! She did tell me tonight, "daddy, you know you have to pay me after I finish my work!"

Got a new toy to help me get through some of the metal work. Couldn't beat the price and all the reviews were great. Just waiting on my shielding gas cylinder so I can get to work.

I'm still waiting on my floor to get in (seems as though Gerson takes all of December off and the first half of January) so found a couple really good deals on some donor doglegs. The red ones are the ones I found first. Got a really good deal on them and the guy I got them from cut them all the way to the A pillar. The blue ones are from another place. I got them for such a great price I feel like I stole them! The blue ones are solid as HELL, but cut short as you can see from the pictures below.

So my question is, would it be a good idea to use the blues ones as a whole and then take the last 4" from the red ones (where it meets the A-pillar) and weld them together? That's what I think would be best, but need some advise from anyone who has done this. If I go this rout, do I have to disassemble the doglegs or can I just weld them in as one piece? I have seen where people have taken them apart to weld them in (mostly seen that with after market repops). Any advise is welcome and will be take seriously. Thanks!!!

Not much of an update, but have decided to use the red doglegs and just repair them. Will probably just try to sell the blue one s and make some of my money back.Best news though, just got word from Monkeynut in Charlotte, my new front floor from Gerson will be shipping this week!!!

Just a small update to let everyone know that I haven't stalled completely on this...FINALLY got my front floor from KlassicFab and I must say, worth the wait and well worth the money. Thanks to MonkeyNut in Charlotte NC for it also. Great bunch of people to deal with.

I finally got my garage/basement cleaned out enough to get the bus inside and out of the elements. I did however have to compromise with the wife to only do the "dirty" work outside. Fair enough if you ask me.Most of what I have been working has been grinding and cutting out the rest of the old rusty floor. Got all but two small places finished and cleaned. Also been surgically dissecting the donor doglegs for replacement. Also took the plunge and started cutting out the drivers dogleg out! Point of no return I guess! Here are a few pictures of the progress. Now that the time is about to change and the weather is getting better, I should get some more progress soon.

And a HUGE shout out to Bryce, Michael and Joel for coming and helping out last weekend. Michael gave me a lot of good guidance on how these doglegs are constructed and how they seem to attach to the a-pillar.

Slow going with limited time, but comments do help me stay on track. All I have done so far with the new welder is a couple of practice welds. Not even going to show those results. LOL! It's been about 5 years since I've done any welding, but it's like riding a bike. Just need to get the settings dialed in.

After effing with these donor doglegs for the last couple weeks, I decided to try something different and order some new ones. Since Gerson quit making early bay doglegs, I was left with either ordering the cheap Klokkerholm repops or the ultra expensive ones from England. I went with the cheaper ones and got them in three days from Bus Depot. After opening the box, I could tell they were very cheaply made, but they are good enough for what I want them for.

I also decided not to use the whole piece for two reasons. 1) I didn't feel like messing with the connection at the b-pillar since mine was still really solid. 2) I have read and seen where the arch of these repops are REALLY bad! And yes, they are awful!

As you can see below, I still have a patch to make, but overall I thing this will work ok.

It doesn't line up perfect, but I think once I start tacking it in, I should be able to bend and tweak it enough to fit close enough.

The outer seems to fit nicely and the door gap is within reason. I think I can live with it being my first time doing any of this kind of work.

vw57drvr wrote:Thats weird. Gerson still has them listed and priced on his website. I thought VW still sold some of these panels?

*Never mind. I see now that they are out of stock. He should take down those pictures.

I agree. I was at Monkeynut at the end of last year in Charlotte and they were the ones that told me he wasn't planning on making them anymore. Really sucks but I'm just glad I was able to make these cheap ones work. May not be perfect, but good enough for me.